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I think this kind of error may happen when some CES configuration settings become very long. In the CES Administration Tool, can you give me the number of "Field Set" you have in the Configuration/Fields section?

This error indicates that a configuration object is invalid in the Administration Tool memory. Recycling the AppPool of the Administration Tool will create new valid configuration objects. Automatic IIS recycling is probably the reason why your "prod" environment started to work without change.

Whoa. For individual fields sets there are 46. I see about 12 that I know could be deleted. The server have looks like it was created by cloning. Web Connector is using the Default Scheme with 2 added fields + preconversion script.

``` Default Scheme The default fields set. Field set for Coveo_core_index - CALCMSPA-domain Field set for Coveo_core_index - CALCMSPA-domain Field set for Coveo_core_index - CALCMSPCD1-domain Field set for Coveo_core_index - CALCMSPCD1-domain Field set for Coveo_core_index - CALCMSPCD2-domain Field set for Coveo_core_index - CALCMSPCD2-domain ... ```

Each Sitecore database (Web, Master, Core...) of each Sitecore instance have its own fields set. Also, when you change the <SourceName> of an index in Coveo.SearchProvider.config file, new fields sets and sources are created but the old ones aren't automatically deleted.

Each fields set have a large list of facet fields, multi-value facet fields and sort fields. The concatenation of all those fields names is stored in the CES configuration. If it becomes too long, it may cause the kind of error you experienced in the Administration Tool.

Deleting old and unused fields sets and sources is a best practice. This will reduce the delay it takes to commit each configuration change.

Unfortunately, deleting a fields set doesn't remove its fields from the facet fields, multi-value facet fields and sort fields lists in the CES configuration because some indexed documents may still use those fields. I asked the developers to implement a cleaning of those fields lists. This may be included in a future release of CES.